US5330827A - Reinforcing fibres and a method of producing the same - Google Patents

Reinforcing fibres and a method of producing the same Download PDF

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US5330827A
US5330827A US07/921,985 US92198592A US5330827A US 5330827 A US5330827 A US 5330827A US 92198592 A US92198592 A US 92198592A US 5330827 A US5330827 A US 5330827A
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fiber
composite material
reinforced composite
material according
polyolefin
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Anders S. Hansen
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CEMFIBER AS
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Danaklon AS
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C04B16/06—Macromolecular compounds fibrous
    • C04B16/0616—Macromolecular compounds fibrous from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B16/0625—Polyalkenes, e.g. polyethylene
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/42—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
    • D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/10—Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
    • C04B2111/12—Absence of mineral fibres, e.g. asbestos
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/91—Product with molecular orientation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S52/00—Static structures, e.g. buildings
    • Y10S52/07—Synthetic building materials, reinforcements and equivalents
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S57/00—Textiles: spinning, twisting, and twining
    • Y10S57/907—Foamed and/or fibrillated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249932—Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2927—Rod, strand, filament or fiber including structurally defined particulate matter

Definitions

  • the present invention relates to fibre-reinforced composite materials, to reinforcing particle-containing polyolefin fibres, and to methods of preparing the fibres.
  • fibres of different types have been employed to reinforce inorganic and organic composite materials.
  • One example of a previously widely used type of fibre is the asbestos fibre, the use of which, however, has been limited in recent years owing to the health hazards of this fibre.
  • plastic fibres of different types have been widely employed.
  • fibres made from polyolefin have been found useful as they are easy and inexpensive to prepare and confer advantageous reinforcing properties to the composite materials in question.
  • the polyolefin fibres have been difficult to distribute evenly in the matrix material and the fixation of the smooth polyolefin material in the matrix material has not been satisfactory.
  • Several researchers have found that incorporation of fine particles in the polyolefin mass constituting the fibres results in fibres which are more easy to disperse and which adhere very well to the matrix material, probably because of voids and protuberances and other irregularities in the fibre surface resulting from the presence of the particles at the surfaces. Examples of such particle incorporation is given by Ellis in European Patent Application No. 0 026 581 and by Firth in European Patent Application No. 0 006 318, wherein a particle content of at the most 10% by weight of the total fibre weight is employed.
  • the present invention relates to polyolefin fibres in which a high concentration of particles (well in excess of 10%, calculated on the total weight of the fibres and the particles) is present, but with substantially none of the particles being exposed at fibre surfaces. Due to special properties conferred to the fibres hereby, the fibres are easy to disperse in the matrix material and become excellently fixed therein. In addition, the fibres confer very advantageous properties regarding strength and flexibility to the matrix materials in which they are present, compared with materials which are reinforced with conventional polyolefin fibres. This is in spite of the fact that the fibres per se do not show any superior properties in relation to the conventional polyolefin fibres regarding strength and bending properties.
  • the present invention relates to reinforcing fibres made from polyolefin or polyolefin derivatives, the fibres having a thickness of 10-100 ⁇ m and containing inorganic particles of a size of 1-10 ⁇ m in an amount of at least 12% by weight, calculated on the total fibre weight, the particles being embedded in the polyolefin or polyolefin derivatives, substantially none of the particles being exposed at fibre surfaces.
  • the inorganic particles are incorporated in an amount of at least 15%, such as at least 17% by weight of the total fibre weight in the reinforcing fibres. Most preferably, the inorganic particles are incorporated in an amount of 17%, calculated by weight of the total fibre weight.
  • the reinforcing fibres may be prepared by a method comprising the following steps:
  • this method may be performed as follows:
  • the fibre components which will be discussed below, are mixed so as to obtain a homogeneous dispersion of the particles in the polyolefin or polyolefin-derived material, i.e. the plastic component.
  • the mixing characteristics e.g. the vigor and time of mixing, depend on the kind as well as on the amount of particles employed. Conventionally, the higher the amount of particles, the longer and more vigorous the mixing has to be. When the amount of particles exceeds about 20%, calculated by weight of the total weight of the fibre components, the particles may be difficult to disperse. If fibres of that high particle content are desired, usually very harsh mixing conditions must be employed.
  • the plastic component i.e. the polyolefin or polyolefin derivative which normally is solid at temperatures under 160° C.
  • the melting may be performed in any suitable equipment, conveniently in the extruder which is used for the subsequent extrusion.
  • the mixing of the fibre components is carried out in the extruder simultaneously with the melting of the plastic component.
  • a homogeneous distribution of the particles is normally obtained within the time required to totally melt the plastic component.
  • the time of melting (and mixing) may be less than 10 minutes, and in most cases about 5 minutes.
  • the mixing temperature will depend on the melting point of the plastic component in question.
  • the particles may also be added to the plastic component during the melting of this component.
  • the mass is extruded through a die of a dimension which is suited to the desired film dimension so as to obtain a film which is subsequently cooled.
  • the polymeric material crystallizes, and the crystallization pattern is dependent on the type of cooling employed as well as on the polyolefin or polyolefin-derived material employed.
  • the crystallized material comprises amorphous and crystalline structures which are mixed among each other. The ratio between the volume of the crystalline and the amorphous areas is conventionally designated the degree of crystallization.
  • the extrusion may be performed so as to obtain a blown film.
  • the plastic mass is extruded through a circular ring, resulting in an air-filled bag of the fibre material.
  • the bag is cooled by passage through a second ring, a cooling ring, after which it is passed through rollers, resulting in the formation of a two-layered film.
  • the rate of cooling is relatively low, resulting in a relatively large degree of crystallization of the plastic component. Also, relatively large crystals are formed.
  • the extrusion may also result in a cast film, where the plastic mass is extruded through a flat die whereby a one-layered film is obtained.
  • This is cooled either in a water bath or by passage through one or more pairs of cold rollers.
  • the temperatures of the water bath and the cold rollers, respectively, are suitably about ambient temperature.
  • the water bath is especially useful as a cooling agent for rather thick films, as this type of cooling is faster and more homogeneous than the cooling through rollers.
  • the extruded film is then subjected to stretching. This is done in order to orient the polyolefin chains of the polyolefin or the polyolefin-derived material substantially unidirectionally so as to obtain a high tensile strength and an increased modulus of elasticity in the direction of the fibres. Also the fibrillation which follows after the stretching is made easier by the stretching.
  • the method employed for stretching the film is not critical, and any method and equipment may be used.
  • the film is stretched in an airheated oven or in a liquid medium such as water or an oil.
  • the temperature of the oven will depend on the type of film to be stretched, but will in most cases be about 130°-200° C., such as about 165° C.
  • the film may be passed through the oven or the liquid medium by means of two pairs of rollers which are situated before (the first pair of rollers) and after (the second pair of rollers) the oven or the liquid medium, respectively.
  • the speed of the second pair of rollers is higher than the speed of the first pair of rollers, resulting in a stretching of the film between the two pairs of rollers.
  • microfibrils are defined as being constituted by crystal blocks in the longitudinal direction of the film which are surrounded by an amorphous area. Normally, the microfibrils are gathered in bundles which are termed fibrils. The microfibrils and the fibrils are oriented parallelly to each other in the direction of stretching. Following the initial necking, the film is further deformed by the stretching so that the microfibrils are displaced and moved further apart from each other.
  • the relation between the speeds of the two pairs of rollers defines the stretch ratio, i.e. the extent of stretching.
  • the film is stretched in a ratio of at least 1:6, such as at least 1:10, and particularly in a ratio of at least 1:15.
  • the film is stretched in a ratio of 1:17. This latter stretch ratio may be obtained e.g. by letting the film pass the first pair of rollers at a speed of 5 m/min. and the second pair of rollers at a speed of 85 m/min.
  • the stretching may cause tensions in the film to develop. These may be relaxed by subjecting the stretched film to heating. Conveniently, this is done by passing the film through an oven in which the film is allowed to shrink. It is important that this heat-setting or relaxation takes place at a temperature lower than the temperature of the stretching.
  • polypropylene which is one of the preferred polyolefin components of the fibres of the invention
  • this heat-setting takes place at about 130° C. After this treatment, the residual shrinking will be very modest (3-5%) at temperatures below 130° C.
  • the fibrillation or the splitting in the longitudinal direction of the stretched film as it may also be defined, is carried out on a knife and/or pin roller with a faster peripheral speed than the speed with which the film is carried along.
  • the pin roller is a cylinder equipped with sticks in the direction of the movement of the film which are provided with closely spaced pins. The fibrillation results in a net-like structure of the film with small fibrils.
  • the polyolefin or the polyolefin-derived material is resistent and thus inactive towards most chemicals, it may be necessary to modify the surface of the fibrillated film so as to obtain a satisfactory interaction of the fibres and the matrix material which they are to reinforce.
  • the surface of the fibrillated film may be modified by heat treatment, and/or subjected to chemical modification, electrical modification, and/or mechanical modification.
  • the chemical treatment may take place in various ways, e.g. by copolymerization, compounding of powder, or by applying a liquid on the surface.
  • the chemical employed is selected according to the properties desired on the surface, e.g. good fixation of fibres to cement.
  • Especially chemical treatments comprising introduction of OH--, COOH-- and/or anhydride groups in the polyolefin component have been found to be advantageous. Examples of chemicals which are suitable for introduction of these groups are, respectively, vinyl alcohol, acrylic acid, and maleic acid anhydrid.
  • corona treatment An example of an electrical treatment which has been found to confer very desirable properties to the film and which is widely used in the plastic fibre production throughout the world, is the corona treatment.
  • This treatment is a vigorous electrical discharge from a special electrode down to the surface of the film.
  • a rather high voltage is required (about 25 KV and 20 KHz) in order for the electrons to get sufficient energy to penetrate the surface.
  • the electrons hit the polymer chains at a high speed many of these chains will be broken, thus giving a possibility of forming carbonyl groups by means of the ozone (O 3 ) in the air.
  • O 3 ozone
  • the mechanical treatment may comprise sandblasting and may, e.g., be carried out in a sandblasting chamber as described in Example 1 hereinafter.
  • sandblasting e.g., be carried out in a sandblasting chamber as described in Example 1 hereinafter.
  • many other useful mechanical treatments exist, the essential feature being to obtain a further splitting of the surface of the film in the longitudinal direction.
  • texturing i.e. making the film surface wavy, e.g. as described below in Example 1, is a very effective means of modifying the surface.
  • the fibres and/or the fibrillated film may be made hydrophilic, hydrophobic or antistatic or may be made more easy to disperse in the matrix material in question.
  • the surface modification comprises treating the fibres and/or the fibrillated film with a surfactant such as a wetting agent, e.g. a so-called “hydrophillic avivage” (also termed “hydrophyllic rewetting agent” or “hydrophillic lubricant”) or an anti-static agent.
  • a surfactant such as a wetting agent, e.g. a so-called “hydrophillic avivage” (also termed "hydrophyllic rewetting agent” or “hydrophillic lubricant”) or an anti-static agent.
  • the surfactant to be used is of a type which will satisfy the qualitative demands of the fibre surface in question.
  • surfactants such as AMOA P 231, Amoa Chemicals, Hinchley, Leicestershire, England, Cithrol A, Croda, Cowich Hall, North Humberside, England, or SW-T, Nissin Kagaku Kenkyosho Ltd., Japan
  • the surfactant is normally employed in the last stage of the fibre preparation process, i.e. prior to cutting. It is typically used in an amount of about 0.15-3% by weight of the fibrillated film material, more typically about 0.4-1.6% by weight of the fibrillated film material.
  • Specific examples of treatment of the fibre surface are given in the Examples which follow.
  • the fibrillated film material which has been subjected to one or more of the modifications or surface treatments discussed above is subjected to cutting so as to obtain fibres of a suitable length.
  • the length of the fibres is at the most 15 mm, more preferably at the most 12 mm, and especially at the most 6 mm.
  • the maximum lengths stated above are to be considered as true maximum lengths for substantially all of the fibres in the mixture. However, a small amount of fibres may be of a length which exceeds these maximum lengths and still be considered to be within the scope of the present invention.
  • the fibres which result from the treatments discussed above are preferably of a width of 20-700 ⁇ m, more preferably 60-300 ⁇ m, and especially about 250 ⁇ m.
  • Fibres which form a network wherein the length of the individual fibres is shorter than the length of the slits between the fibres have been found especially useful. This is the case, e.g. when the film is to be cut into chopped fibres, where it will be advantageous that the slit length is larger than the fibre length, so as to avoid interconnection between the individual fibres.
  • the particles are totally embedded in the polyolefin or polyolefin-derived material so that the surface of the fibres appears smooth, having no bulges or other irregularities owing to the presence of the particles. It appears from this that the size of the particles must be correlated to the final thickness of the fibres so that the largest dimension of the particles, in the case of compactly formed particles the diameter, is smaller than the final fibre thickness. Without limiting the scope of the present invention but being stated as a rule of thumb, the largest dimension, or the size of the particles, is at the most about one third of the final fibre thickness. As stated above, the fibres are of a thickness in the range of 10-100 ⁇ m, and are preferably of a thickness in the range of 20-80 ⁇ m.
  • the fibres are of a thickness of 35 ⁇ m.
  • the inorganic particles are of a size in the range of 1-10 ⁇ m.
  • the lower limit is qualified as particles smaller than 1 ⁇ m are difficult to disperse homogeneously throughout the polyolefin or polyolefin-derived fibre component.
  • the higher limit is based on practice and also on the above discussed relations between fibre thickness and particle size.
  • the inorganic particles are of a size in the range of 2-7 ⁇ m, in particular 3-5 ⁇ m.
  • the inorganic particles are conveniently of a type which do not damage the equipment used for the preparation of the fibres. Normally, the die of any extruder used will be sensitive to hard materials, such as metals and other correspondingly hard materials, which are passed through the die. Thus, the inorganic particles are conveniently selected from rather soft materials (or, expressed in another manner, materials which will not damage the extruder die to any substantial extent) which in addition fulfil the desired properties discussed above, i.e. the hydrophilicity and the particle size. Examples of suitable inorganic particles are chalk, talc, silica, mica, cement, barium sulphate, glass, and a dyeing agent, e.g. TiO 2 .
  • the fibres are constituted by a plastic polymer material, such as polyolefin, which is constituted by carbon and hydrogen, or a polyolefin derivative.
  • the polyolefin is selected from polypropylene and polyethylene.
  • Polypropylene is a well-known constituent of plastic fibres and has been used as such for many years owing to its resistance towards acids and bases, its advantageous strength properties, its low density, as well its low price.
  • the properties of a typical polypropylene fibre, commonly known as KRENIT®, is illustrated in the Examples which follow.
  • polyolefin derivatives has proved to be useful as particle-containing fibre constituents.
  • vinyl polymers such as polyvinyl alcohol comprised of carbon, hydrogen, and oxygen, as well as acrylic acid and organic acid anhydrides, such as maleinic acid anhydride.
  • An especially advantageous fibre composition comprises polypropylene in an amount of 83% and chalk in an amount of 17%, calculated by weight.
  • Another advantageous fibre composition comprises polypropylene in an amount of 86% and barium sulphate in an amount of 14%, calculated by weight.
  • the fibres may further comprise other additives in order to obtain properties which are suited to the use in question.
  • additives may comprise antioxidants and UV stabilizers which may avoid decomposition of the plastic materials of the fibres.
  • the antioxidants and UV stabilizers are added in an amount of 0.5-5% by weight of the total fibre composition, and examples of suitable antioxidants and UV stabilizers are Irganox and Chimnasorb, respectively.
  • flame retardants may be employed. These may be combinations of an aromatic bromo-containing composition and antimony trioxide (Sb 2 O 3 ), for example Sandoflam 5071, Sandoz, Switzerland.
  • the particle-containing fibres of the present invention are preferably used as constituents in inorganic matrix-based materials or composite materials such as building materials, typically in order to improve the physical properties of these materials.
  • the fibres may conveniently be used as substituents for asbestos fibres.
  • the composite materials comprise an inorganic binder which may be cement, e.g. Portland, gypsum, puzzolane such as fly ash, silica, wollastonite, and/or bentonite. Additionally, the composite material may contain a superplasticizer, e.g. a compound of sulphonated naphthalene.
  • cement-based matrix materials such as concrete and mortar.
  • the fibres are typically supplied in an amount of 0,1-10% by weight of the total composite material, such as about 5% by weight of the total composite material, and a fibre content of about 3% by weight of the total composite material has been found especially useful.
  • the amount of fibres employed is of course dependent on the type of composite material to be produced. Also, the methods of producing the composite materials will vary with the kind of composite material to be prepared.
  • Composite materials, in which the particle-containing fibres of the present invention may be employed, are e.g. such materials disclosed in U.S. Pat. No. 4,636,345 (Jensen et al).
  • FIG. 1 illustrates the principle of a four point loading test of fibre reinforced composite materials.
  • the plate 1 is placed in a testing machine of any convenient type and subjected to loadings as illustrated.
  • P is the magnitude of the total load applied to the plate.
  • FIG. 2 is a graphic illustration of the stress ( ⁇ )/strain ( ⁇ ) properties of the plates of Example 2 which resulted from the four-point loading test illustrated in FIG. 1. From this graph, the modulus of elasticity, which is the slope of the first linear part of the graph, and the energy of rupture being the area below the graph, are determined.
  • the preparation of fibres comprised most of the following steps:
  • the blow ratio i.e. the ratio between the diameter of the bag and the diameter of the circular die being 1.02.
  • the extruded film was cooled by passage through a cooling ring which was placed on the top of the die. After the cooling the air-filled film bag was passed through a pair of niprollers at a speed of 5.5 mm/min. so as to drive out the air and produce a double-layered film.
  • the film was passed through a second pair of rollers situated below the nip rollers.
  • the film was then passed through an oven of a temperature of 165° C. and a third pair of rollers situated onthe other side of the oven.
  • the blown film was stretched in the oven as thespeed of the third pair of rollers was higher than the speed of the second pair of rollers.
  • the actual stretching ratio, i.e. the ratio between the speed of the two pairs of rollers, for each of the film variants prepared is stated in Table I.
  • the stretched film was passed over a pin roller having 26 pins/cm stick.
  • the number of pin rows of each cm of the roller surface was 0.55.
  • the filmto be fibrillated was passed over the pin rollers at a speed of 230 m/min.
  • the heat setting of the film was performed by passing the film through an oven heated with air of a temperature of 130° C.
  • the film was movedat a speed of 92 m/min.
  • the film was moved at a speed of about 87.0 m/min, corresponding to about 95% of the speed of the film during the heat setting.
  • the film was passed through a sand-blasting channel constructed by applicants, wherein the film was bombarded with fine glass spheres of a diameter of 45 ⁇ m. This treatment resulted in a more rough surface of the film and furthermore a further splitting of the film in the direction of the film movement.
  • the surface of the film was made profiled with a wave structure in the longitudinal direction by pressing a heated cable having a waved surface (having 100 waves per 10 cm) against the film.
  • the pressure created by therollers on the film was gradually increased, after which the pressure was released and the cable was removed. This procedure is also known as the stufferbox technique.
  • the surfactant was added to the film when it was passed through a pair of lubricant application (lick) rollers, and the amount of surfactant to be deposited on the film was regulated by the speed of rotation of the rollers.
  • lick lubricant application
  • the film was subjected to a strong electric discharge by passage under an electrode of the type Vetaphone T1200.
  • the voltage of the electrode was about 25 KV and 30 KHz (12 KW).
  • This electric treatment is also known as acorona treatment.
  • the cutting of the film was performed by passing the film tangentially overa wheel of a diameter of 468 mm on which knives were placed radially.
  • the film was pressed against the knives by a roller-derived pressure.
  • the lengths of the resulting fibres were equal to the distance between the radially placed knives.
  • the fibres containing particles possess less desirable properties than the fibres without particles (the PP fibre).
  • the values of the modulus of elasticity and the strength of the PP fibre are significantly higher than the values of the corresponding properties of the particle-containing fibres and the ultimate elongation which may be defined as the resistance to strain before rupture.
  • the polyolefin fibres are the fibres of Example 1.
  • the water of the suspension was sucked off by a low pressure of 0.27 bar, after which the filter cake was placed in a press where it was subjected to a short pressure of about 10 MPa.
  • the permeability of the material in its unhardened form was determined by means of the time of filtration. The time of filtration, i.e. the time of the low pressure treatment, of each of the plate preparations was noted.
  • the plates were hardened in a wetting box for 24 hours followed by hardening under water at ambient temperature for 6 days.
  • the plates prepared by the above process were of a length of about 203 mm, a width of about 76.5 mm, and a thickness of about 5 mm.
  • the mechanical properties of the fibre-reinforced plates were investigated by subjecting the plates to a 4-point loading test as shown in principle in FIG. 1. 10 plates of each of the variants were tested; five of the plates were tested in a wet state and the 5 remaining plates were tested in a dry state, which was obtained by subjecting the plates to drying for 2 days in an oven of a temperature of 110° C.
  • the stress ( ⁇ )/strain ( ⁇ ) properties of the plates as determined by the4-point loading test was plotted in a graph which in schematic form is illustrated in FIG. 2.
  • the stress/strain values at the point, where the proportionality between the stress and the strain changes ( ⁇ k , ⁇ k ) as well as the stress/strain values at the point of maximum loading ( ⁇ m , ⁇ m ) were read. From these values, the modulus of elasticity and the energy of rupture were calculated.
  • the modulus of elasticity is defined as the slope of the firstlinear part of the graph, whereas the energy of rupture is defined as the area below the graph up to the maximum loading and is calculated accordingto the formula
  • Fibre-reinforced plates were prepared by extruding a slurry consisting of
  • the percentages stated are the weight percentages calculated by weight of the solid part of the slurry.
  • the polyolefin fibres are the fibres of Example 1, and the type of fibres employed in the preparation of the plates is stated in connection with the statements of the properties of the plates.
  • the plates were prepared as follows:
  • the fly ash, silica, polyolefin fibres, Mighty® superplasticizer, and water were thoroughly mixed in a mixer conventionally used in the baking industry. Cement and Wollastonite were added to the resulting homogeneous mass, and the mixing was continued until these components had become totally dispersed in the mass.
  • the resulting plastic mass was transferred to an extruder (Linden) and was extruded through a flat die directly into a rolling mill so as to obtain a thickness of the resulting plates of about 4.5 mm.
  • the plates were cut out in pieces of dimensions of about 300mm ⁇ about 600 mm and these were hardened for 16 hours in a hardening chamber at a temperature of 80° C.
  • test specimens of dimensions of 202 ⁇ 600 mm were cut out, and these were tested in a storage-humid state at ambient temperature.
  • the test specimens were subjected to a 4 point loading test.
  • the test specimens were cut out so as to obtain a rupture along the direction of production, and a rupturetransversely to the direction of production.
  • the stress-strain properties defined above, i.e. ⁇ k , ⁇ k and ⁇ m , ⁇ m were determined.
  • the modulus of elasticity, the energy of rupture, and the density of the plates were determined as described above.
  • the results i.e. the mean value and the standard deviation, are stated in Table IV below.
  • the results of the testing, where the rupture occurs along the direction of production is designated A1
  • the results of the testing, where the rupture occurs transversely to the direction of production is designated T.
  • the results show that the plates containing the particle-containing fibres of the present invention have superior properties regarding elasticity, strength, and strain when compared to plates made with conventional polypropylene fibres.
  • fixation between fibre and matrix is an important parameter in the development of plastic fibres as good fixation is a prerequisite for the possibility of utilizing the mechanical properties of the fibres, but at the same time, this parameter is very difficult to measure.
  • the measuring of the fixation between plastic and cement was performed on the extruded, unstretched film from which each of the fibre variants of Example 1 was prepared.
  • a pure cement paste (Rapidcement, water/cement ratio 0.5) was applied to the plastic film and to the surfaces of two circular steel specimens of an inner diameter of 44 mm and 70 mm, respectively.
  • the specimens were placed concentrically on either side of the plastic film so that the cement on either side of the plastic film andthe cement of the respective steel specimens adhered to each other. 10 suchtest specimens were prepared and the cement of the specimens was hardened in a wetting box at room temperature.

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  • Curing Cements, Concrete, And Artificial Stone (AREA)
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  • Preliminary Treatment Of Fibers (AREA)
  • Nonwoven Fabrics (AREA)
  • Chemical Treatment Of Fibers During Manufacturing Processes (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
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US6071451A (en) * 1997-12-31 2000-06-06 Kimberly-Clark Worldwide, Inc. Process for making a nonwoven, porous fabric from polymer composite materials
US6090472A (en) * 1997-12-31 2000-07-18 Kimberly-Clark Worldwide, Inc. Nonwoven, porous fabric produced from polymer composite materials
US6261674B1 (en) 1998-12-28 2001-07-17 Kimberly-Clark Worldwide, Inc. Breathable microlayer polymer film and articles including same
US6429261B1 (en) 2000-05-04 2002-08-06 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6444214B1 (en) 2000-05-04 2002-09-03 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
WO2003027038A1 (fr) * 2001-09-25 2003-04-03 W.R. Grace & Co.-Conn. Compositions fibreuses susceptibles d'etre pompees et mesurees a l'aide d'un fluide
US6548592B1 (en) 2000-05-04 2003-04-15 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
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US5643991A (en) * 1995-05-12 1997-07-01 Eastman Chemical Company Copolyester compositions containing carbon black
US5753368A (en) * 1996-08-22 1998-05-19 W.R. Grace & Co.-Conn. Fibers having enhanced concrete bonding strength
US6071451A (en) * 1997-12-31 2000-06-06 Kimberly-Clark Worldwide, Inc. Process for making a nonwoven, porous fabric from polymer composite materials
US6090472A (en) * 1997-12-31 2000-07-18 Kimberly-Clark Worldwide, Inc. Nonwoven, porous fabric produced from polymer composite materials
US6261674B1 (en) 1998-12-28 2001-07-17 Kimberly-Clark Worldwide, Inc. Breathable microlayer polymer film and articles including same
US6630558B2 (en) 1998-12-31 2003-10-07 Kimberly-Clark Worldwide, Inc. Ion-sensitive hard water dispersible polymers and applications therefor
US6444214B1 (en) 2000-05-04 2002-09-03 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6579570B1 (en) 2000-05-04 2003-06-17 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6548592B1 (en) 2000-05-04 2003-04-15 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6429261B1 (en) 2000-05-04 2002-08-06 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6814974B2 (en) 2000-05-04 2004-11-09 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6653406B1 (en) 2000-05-04 2003-11-25 Kimberly Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6713414B1 (en) 2000-05-04 2004-03-30 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6683143B1 (en) 2000-05-04 2004-01-27 Kimberly Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6815502B1 (en) 2000-05-04 2004-11-09 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersable polymers, a method of making same and items using same
US6599848B1 (en) 2000-05-04 2003-07-29 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6602955B2 (en) 2000-05-04 2003-08-05 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6835678B2 (en) 2000-05-04 2004-12-28 Kimberly-Clark Worldwide, Inc. Ion sensitive, water-dispersible fabrics, a method of making same and items using same
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ES2010156A4 (es) 1989-11-01
GR3005187T3 (fr) 1993-05-24
IE61332B1 (en) 1994-11-02
WO1989002879A1 (fr) 1989-04-06
IL87831A (en) 1991-11-21
PT88613A (pt) 1989-07-31
EP0310100B1 (fr) 1992-04-29
IS1543B (is) 1994-06-08
KR890701806A (ko) 1989-12-21
MX13223A (es) 1994-02-28
EP0310100A1 (fr) 1989-04-05
JPH03501393A (ja) 1991-03-28
PT88613B (pt) 1993-07-30
ES2010156T3 (es) 1993-06-16
NZ226366A (en) 1990-11-27
DE310100T1 (de) 1989-10-05
CS638888A3 (en) 1992-11-18
AU2544188A (en) 1989-04-18
MY103915A (en) 1993-10-30
SK278457B6 (en) 1997-06-04
CA1325087C (fr) 1993-12-14
DE3870564D1 (fr) 1992-06-04
IS3395A7 (is) 1989-03-31
IL87831A0 (en) 1989-03-31
GR890300155T1 (en) 1990-03-14
DK81590D0 (da) 1990-03-30
IN172063B (fr) 1993-03-27
PH24341A (en) 1990-06-13
IE882861L (en) 1989-03-30
DK169699B1 (da) 1995-01-16
JP2688434B2 (ja) 1997-12-10
HK46296A (en) 1996-03-22
KR960000788B1 (ko) 1996-01-12
DK514687D0 (da) 1987-09-30
DK81590A (da) 1990-05-29
ATE75464T1 (de) 1992-05-15
CZ277749B6 (en) 1993-04-14

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